High Power Hg Target Conceptual Design Review Hg

High Power Hg Target Conceptual Design Review Hg Target Design P. T. Spampinato V. B. Graves T. A. Gabriel Oak Ridge National Laboratory February 7 -8, 2005

Outline · Design Constraints · Original Hg delivery concept & issues · Proposed new baseline delivery system · Hg flow analysis in new baseline system · Issues & recommendations OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 2

Design Constraints · Hg Jet - 1 cm dia, 20 m/s (1. 57 liter/s, 24. 9 gpm) in same direction as beam - Free jet created inside 15 cm magnet bore - Smooth, steady-state jet duration overlaps 1 -sec max field duration · Integrate optical diagnostics · Materials compatibility with Hg · No target equipment on up-beam end of magnet · Period between beam shots approximately 30 minutes to allow magnet cooling · Component module size limitation is 1. 3 m x 3 m (facility issues) OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 3

Experiment Geometric Configuration · Experiment is prototypic of a N. F. facility target layout - Magnet tilt (wrt beam) = 66 mrad (3. 8°) - Hg jet tilt (wrt magnet axis) = 100 mrad (5. 7°) - Hg jet center intersects beam center at Z=0 OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 4

System Overview Solenoid Intermediate Beam Stop Proton Beam Hg Delivery System OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 5

Original Hg Delivery System Pump Motor Secondary Containment Sump Tank Target Module Centrifugal Pump Hg Jet Containment OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 6

Pump Issues · Pump adds heat to Hg - Pump delivers nominal 51 bhp at 23% efficiency (60 bhp max) - Magnetic coupling losses 5. 4 hp - Heat energy into mercury · Lost. HP = (bhp - mag)*(1 - eff) + mag = 40. 5 hp (30 kw) · With an assumed Vol=12 liter, ΔT=2. 4°F/sec (1. 3°C/sec) due to pump heating only · Max available pump output pressure is 750 psi (50 bar) - Estimated piping system pressure drop 800 -850 psi OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 7

Pump Energy Balance OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 8

Possible Solutions · Heat issue - Increase Hg volume (ΔT decreases linearly with Hg mass) - Add heat exchanger for system testing · May not be needed during CERN tests · Pump discharge pressure issue - Vendor specified pump to provide max DP - Investigate alternative Hg delivery systems Nature of experiment lends itself to non-continuous flow approach, so… OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 9

Alternative Hg Delivery System Hydraulic Fluid Cylinder (3000 psi) Hg Inlet Hg Cylinder (1000 psi) Hg Discharge OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 10

Syringe Size Comparison Hydraulic Pump & Reservoir OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 11

System Energy Comparison OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 12

Syringe Performance Benefits · Piston-driven jet has excess capacity to overcome flow losses · No significant heat imparted to Hg by piston - Heat losses isolated to hydraulic system - Flow losses identical to those in pump system - No heat exchanger required · Syringe design may be smaller than shown, depending on Hg volume required - 1. 6 liter/s → 48 liter for 30 sec, 24 liter for 15 sec - Concept shown in size comparison was sized for 30 sec jet · Lower power requirements - 20 hp hydraulic pump motor vs. 60 hp centrifugal pump motor OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 13

Hg Cylinder Experience · SNS test stand used pneumatic cylinders to cycle candidate drain valves several thousand cycles with no leaks · Low-pressure application with automated controls OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 14

New Baseline Target System Hg Cylinder Vent Line Sized for 20 sec jet Hg Return Hydraulic Lines Ball Valve Hg Supply Checkvalve Position Sensor Drain OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 15

Sump Tank Level Sensor Hg Extraction Port · 22" SS pipe · Hg inventory - 36 liter, 1068 lb - 6 inch depth · Incorporates float-type level sensor, Hg fill & extraction ports · Thermocouple on sump exterior or in direct Hg contact Sight Glass Hg Fill Port Deflector Plate · Potential use as storage tank for shipping OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 16

Syringe SS Flex Metal Hoses – 1" and 6" · 8" Hg cylinder, 4" hydraulic cylinders, 39" strokes - Sizes chosen based on costs · Position sensor allows actual flowrate calculations · Checkvalve prevents backflow into sump Checkvalve - Must remain submerged throughout experiment to prevent air intake in cylinder 1" SS Discharge Pipe · Discharge pipe will require structural supports Drain Valve & Cap Ball Valve – Manual or Remote Position Sensor OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 17

Hg Supply Tubing Hg Supply 1" SS Rigid Tubing Flange or Weld Interfaces Tubing Restraints Tubing Welded To Plenum OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 18

Hg Plenum Single Tube Dual Supply Lines · Purpose is to provide reservoir to allow Hg to change direction in confined space · Open chamber with nozzle exit and beam thru-tube Secondary Containment Interface Point Plenum · Raised bottom for drainage Nozzle Beam Thru-tube Bottom Flush w/ Exit Beam Window OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 19

Plenum Issue · Trapped air in plenum - Swept out with Hg - Compressed and acts like spring · Solutions - Evacuate system prior to operation · Hg vapor issue - Provide means to quickly move air out nozzle OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 20

Plenum Structural Design · Static FEA performed using pressure load of 850 psi on interior surfaces · Minimum FOS = 6 around beam thru-tube · Flow analysis presented by M. Wendel OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 21

Plenum/Nozzle Integration · Plenum & nozzle welded to primary containment – no nozzle replacement · Nozzle side restraints resist field-induced motion in Hg · Length set at 10 X dia = 4" · Changes to inlet/exit required based on flow analysis OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 22

Primary Containment – Right Side Weldment 0. 25" SS Plate Flared Outside Magnet O/A Length 63" Optical Diagnostics Interface to Secondary Containment OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 23

Primary Containment – Left Side Reflector Assemblies 5" x 5" Hg Exit OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 24

Primary Containment – Side View Jet Deflector Primary Containment Anti-vibration Mechanism Hg Jet Secondary Containment Z=0 Viewport OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 25

Deflector · Purpose is to enhance Hg drainage into sump tank by minimizing splashing and Hg drops back into magnet bore · Material is Ti 6 Al 4 V, same material used for beam windows · Designed as flat plate with low angle of incidence - Some curvature may be needed to aid in flow control - Princeton tests can be used to provide design feedback · Stress calculation indicates Hg jet impact force <100 lb - Deflector thickness of 0. 1" provides FOS=5. 5 OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 26

Primary Containment Cross Section Sight Glass Primary Containment Sight Glass Cover Hg Jet Hg Supply Reflector Optics Secondary Containment OD=6. 18" (157 mm) Magnet Bore ID = 162 mm OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 27

Viewports Fused Silica Disk · Optical viewport laminated with radresistant gaskets Cover Plate · Mechanically fastened cover plate · Structural rigidity of disk needs further analysis Gaskets OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 28

Primary Containment As Supplied · Viewport components fabricated as part of primary containment · Windows & optical diagnostics to be provided by others · Interface sketches will be provided in Final Design OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 29

Secondary Containment · SS sheet metal enclosure around entire primary system Hydraulic Connectors Lid w/ Gasket Optics Port · Contains Hg leaks, provides access to monitor Hg vapors · Provides access to optical diagnostics, hydraulics, and sensors Hose Clamps & Sleeve · Incorporates beam windows Heater Foil Electrical Leads · 3 components: hydraulics box, target cover, connecting rubber sleeve OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 30

Hg Target System · Secondary tank dimensions 102 x 36 x 45" (2. 6 x 0. 9 x 1. 1 m) without support base · Need to reduce footprint - Facility limits are 3 m x 1. 3 m OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 31

Mechanical Design Issues · Nozzle design - More analysis needed Nozzle/deflector designs need validation Air entrapment in plenum Removable nozzle · Viewports - Structural rigidity of viewport optics - May require testing · System sizing - Footprint for 20 sec syringe too large · Minor width reduction possible · Need to decrease required stroke - For 8" cylinder, 1 sec jet duration requires 1. 9" stroke · Reducing jet duration by 1 sec reduces overall cylinder length by 3. 8" - Recommend reducing max jet duration to 15 s OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 32

Hg Flow Analysis · Piping analysis performed using AFT Fathom 5. 0 · Results shown separately OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 33

Recommendations · Change baseline Hg delivery system to syringe approach · Size syringe & sump tank with capacity for 15 second jet · Perform additional nozzle simulations and analyses · Perform Hg flow tests to provide needed design feedback OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 34

Syringe Layout OAK RIDGE NATIONAL LABORATORY U. S. DEPARTMENT OF ENERGY Conceptual Design Review 7 -8 Feb 05 35